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Flight Design Issues Service Bulletin For CTSL

Covers Installation Of Starter Solenoid With Large SLA Battery

Flight Design has issued a service bulletin covering the installation of the starter solenoid on many CT and CTLS models. According to the document, some CTLS are equipped with a larger sealed lead acid battery, which requires a different location of the starter solenoid. Under certain unfavorable combination of tolerances, contact of the starter solenoid may contact the throttle cable housing, which in return gets worn through over time. An unprotected electric short circuit may be the result.

The bulletin estimates that inspecting the solenoid installation should take about 10 minutes, while corrective action, if required, would take about two hours to complete. Both the inspection and correction must be done by an A&P Mechanic,LSA Repairman, Owner/Operator with Sport Pilot certification or higher, Part 145 Repair Station, Flight Design Service Center.

Conduct of this SB must be logged in the aircraft documentation by A&P Mechanic, LSA Repairman, Owner/Operator with Sport Pilot certification or higher, Part 145 Repair Station, or a Flight Design Service Center to return the airplane to service.

To inspect the solenoid installation:

  • Open the cowling
  • Identify the throttle cable housing of the right carburetor
  • Identify the starter solenoid
  • Determine the distance between Bowden wire and contacts of the solenoid
  • Distance should be at least 15mm-1/2 inch (a finger should fit in between)

Corrective procedure:

  • Disconnect battery
  • Detach solenoid from firewall
  • Turn solenoid by 180 degrees (need to detach starter wiring temporarily)
  • If needed prepare an adaptor plate to relocate the solenoid for correct distance to throttle cable housing.
  • Properly attach solenoid and starter wiring.
  • Reconnect battery.
  • Close cowling.

(Image from Flight Design news release)

FMI: Service Bulletin

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